I'm ready to build my engine hatch. It is about 7'wide and 3' length and is supported on the sides and back( not the front). I am thinking of using 3/4" starboard or starboard XL white. I need to buy a sheet of this, Does anyone have a good supplier for this? And price and shipping to Philadelphia PA area. The best I found is from Total Plastic for a sheet of starboard XL 60"x96" sheet for $323 + shipping of ?$100-150.

The starboard XL is a little lighter than the std. starboard. 3/4" is 109 pounds vs. 135. The piece I need is about 21 sq.ft. so about 60 pounds vs. 80 pounds.

Cobra: Check out post 13, unless you got money to burn. The lighter starboard may be less dense, and therefore offers less strength, if that is required in your case. As your's is not supported in the front, I'd think that is the case. Can you attach a backing board or support under the front of the sundeck to add strength?

heres my 2 cents Starboard and HDPE are not the exact same they are similiar HDPE is somewhat cheaper but can be attacked by the sun . Starboard is more expensive and resist the sun but since it wil be covered by the sunpad that is not a concern, I used the hdpe on my hatch and seats ect. this is the way to go, just my 2 cents.

did you make a complete new hatch.....or did you replace the wood in the fiberglass tray??........doug

Codered: The local plastics dist stocked HDPE in both UV protected and not, and Matt-finished and smooth. I only requested HDPE, and they asked which types I wanted. So, in it's purest compound, it's probably not UV resistant, but it was easy to find HDPE that is.

BTW, a lot of plastic cutting boards are also HDPE, as it is food-safe. Most of these are white, and seldom discolor. In fact, I think the cutting boards at Subway sandwich shops are too (just a guess).

I found a local plastic dist. 20 minutes away who has a 4'x8' sheet of HDPE 3/4" white for $176. I think that I'm off to get the material to build a hatch.

What about scoops? Any recommendations on scoops that'll hold up? Important as a lot of time is spent partying on the back so it's gotta hold up to the occasional drunk.

Suppliers? Prices?

The stuff I used was called Shipboard, supposedly the exact same thing as Starboard, but less money. I used the light stuff. Real easy to work with. I used a leftover piece to rebuild the swim step on my fishboat.

Chart, what bit did you use in the router?

Here's my tray and the shipboard layed in to check on the fit. I should have the upholstered pad back this week.

Notice the aluminum stock to strengthen the hinge areas. I have some quarter inch Hardiboard to bring the other areas up to the same height.